Vapor barrier and cavity seal

ABSTRACT

A vapor barrier and cavity seal includes a head attached to a body. The seal closes a cavity between an interior framed wall and an exterior wall or veneer of a building. The head includes a rounded surface opposite the body and has a width that is greater than the width of the cavity and is disposed to bridge across the entire cavity. The body is square or rectangular in shape to easily fit between the interior and exterior walls within the cavity. The seal may include a foam polyethylene or is formed from a closed cell, soft, flexible non-gassing rod of material that is easily extruded. It may be provided in various dimensions and densities depending on the cavity or expansion joint size required or needed to be filled. Typically, the seal may be used on door and/or window jambs where a 1″ or 2″ gap is required between a brick veneer and framing when a vapor barrier is specified in construction specifications.

There are no related patent applications.

The subject matter of the present invention did not receive federalgovernment research and development funding.

BACKGROUND OF THE INVENTION

The present invention generally relates to a vapor barrier and expansionjoint for use in modern construction. More particularly, the inventionrelates to a vapor barrier that is t-shaped in profile to ensure acomplete vapor barrier between an interior and exterior wall. A bodyportion of the vapor barrier extends into a cavity that exists betweenthe interior and exterior walls of a building; while a head portion ofthe barrier spans across the cavity to ensure that the cavity is sealed.

Many modern buildings are constructed with an exterior wall or veneer ofnonstructural facing that typically comprises brick, concrete, stone,tile, metal, plastic, vinyl or other material. During construction, theveneer is attached to a backing that fastens the veneer to the interiorwalls of the structure. The veneer or exterior wall is parallel to theinterior wall. Many building codes require that a cavity be providedbetween the interior wall and the veneer to prevent condensation fromcollecting on the interior walls.

Different types of building construction materials have differentcoefficients of thermal expansion resulting in differential movementbetween the materials that comprise the interior walls and exterior wallor veneer. Since air has insulating properties that increase the totalinsulation rating of the building walls, including a cavity between theinterior wall and the veneer adds an insulating effect. This cavity alsoprevents the veneer from cracking when the interior and exteriortemperatures are different or when the expansion/contraction of theinterior and exterior wall materials is different.

A vapor problem may be created when a cavity is provided between theinterior and exterior walls. When a vapor pressure differential exists,water vapor movement will move relatively quickly through commonbuilding materials. For example, when vapor passes through a wall thatis warm on one side and cold on the other, the vapor may reach its dewpoint and condense into water. However, if the flow of vapor is impeded,the vapor may not reach a low enough temperature for condensation tooccur. Likewise, if cooled air moves through a cavity between theinterior and exterior wall, condensation may occur.

Many building materials are adversely affected by water. For example,wood expands when its moisture content is increased. Increasing themoisture content in wood may result in warping, twisting or wood decay.Water also corrodes metal which may cause an expansion of the surface ofmetal as well as a decrease in structural integrity of the metal. Theinsulating value of most building materials decreases with the presenceof free water. It is therefore important to provide vapor barriers andexpansion joints in many modern buildings.

In the prior art, paper and backer rod have been used to create vaporbarriers between the interior and exterior walls of a building. Forexample, the interior wall or framing may be wrapped with a paper suchas that sold by Dupont® under the name of Tyvek® before the veneer orexterior wall is constructed. Backer rod is a cylindrical shapedmaterial that is disposed between the interior and exterior walls. It iseasily realized that a cylindrical rod disposed into a rectangularopening may result in inadequate sealing of the cavity between thewalls. Moreover, it is very difficult and time consuming to either wrapthe interior wall or ensure that the backer rod is properly disposedwithin the cavity since the distance between the cavity may vary if theexterior wall is not plumb or true with the interior wall.

Thus, there is a need to have a vapor barrier that spans the entiredistance of the cavity that exists between an interior and exterior wallof the building to assure a proper vapor seal.

SUMMARY OF THE INVENTION

The present invention is a vapor barrier for sealing a cavity between anexterior and interior wall in a building. The barrier may also serve asan expansion joint when disposed between parts of a horizontal membersuch as a floor or the like. The barrier includes a head and body. Thehead is attached to the body and includes an arcuate surface oppositethe body. The body is square or rectangular in shape to easily fitbetween the interior and exterior walls within the cavity. The width ofthe head is larger than that of the body. The barrier seal may be easilyformed by extruding it. When taken in profile, the seal is t-shaped.

In the preferred embodiment, the seal comprises a foam polyethylene oris formed from a closed cell, soft, flexible non-gassing rod of materialthat is easily extruded. It may be provided in various dimensions anddensities depending on cavity or expansion joint size required or neededto be filled. The seal may be used on door and/or window jambs where a1″ or 2″ gap is required between a brick veneer and framing when a vaporbarrier is specified. If the seal is used as an expansion joint, it maybe formed from a high density rubber or similar material that withstandstraffic, and used in expansion joints in floors, parking decks and thelike.

It is an object of the invention to provide a vapor barrier thatprovides superior sealing qualities to those of the prior art. The headspans and extends across the entire width of the cavity to ensure aproper vapor seal thereby preventing air and vapor flow through thecavity.

It is another object of the invention to provide a vapor barrier that iseasily installed into a cavity between an interior framed wall and anexterior wall or veneer. The body of the seal fits easily within thecavity; while ends of the head extend across the entire width of thecavity to assure a complete seal.

It is another object of the invention to provide a vapor barrier that ist-shaped in profile. The vapor barrier includes a first portion having awidth greater than a second portion. The width of the second portion issubstantially equal to the width of a cavity that is to be filled by thebarrier. Thus, the second portion is inserted into and substantiallyfills the cavity; while the first portion spans the entire width of thecavity to overlap on both an interior and exterior wall of a building.

It is another object of the invention to provide a vapor barrier that iseasily formed by extruding the vapor barrier to produce seals havingdifferent dimensions and densities to accommodate different sizedcavities.

It is a further object of the invention to provide a vapor barrier andseal formed from a closed cell, soft, flexible non-gassing material thatis easily extruded.

These and other objects of the invention and advantages of the inventionwill be set forth, appear in part or become apparent after consideringthe specification and accompanying drawings. It is to be realized thatthe following embodiments of the invention have been represented intheir simplest form for ease in understanding the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an elevation view of the present invention taken from an end.

FIG. 2 is a perspective view of the present invention shown in FIG. 1.

FIG. 3 is an end view of the present invention installed between aninterior and exterior wall.

FIG. 4 is a perspective view of the present invention shown in FIG. 3.

FIGS. 5-7 depict various applications where the present invention may beused in modern construction.

DETAILED DESCRIPTION OF THE INVENTION

The following is the preferred embodiment or best mode for carrying outthe invention. It should be noted that this invention is not limited bythe discussion of the preferred embodiment and should only be defined bythe appended claims.

FIG. 1 is an elevation view of the vapor barrier and cavity seal 1. Theseal 1 is defined by a head 2 comprised of an arcuate or curved surface7 and having ends 3 a and 3 b. A body 4 is attached to the head 2 and isdefined by parallel sides 5 a and 5 b. The width of the head w_(h) isgreater than the width of the body w_(b). The vapor barrier and cavityseal 1 includes a length as shown in FIG. 2. Thus, the seal 1 may beprovided on a roll or in stick form and cut to a desired length.

FIGS. 3 and 4 show the vapor barrier and cavity seal 1 in use. A cavity12 is provided between an interior wall 10 and an exterior wall 11. Thewidth of the cavity 12 is defined by w_(c). The width of the cavityw_(c) is substantially equal to the width of the body w_(b). Thus, thewidth of the head w_(h) is greater than the width of the cavity w_(c).

In use, the body 4 of the seal 1 is disposed within the cavity 12; whilethe head 2 extends across the cavity 12. Ends 3 a and 3 b are positionedin contact with surfaces 10 a and 11 a to ensure a complete seal. Inuse, the vapor barrier and cavity seal 1 provides a redundant seal. Afirst seal is created between sides 5 a, 5 b and walls 10, 11. A secondseal is created between sides 3 a, 3 b and surfaces 10 a, 11 a asindicated by numerals 30 a and 30 b. Thus, the seal 1 is a redundantseal.

Specific examples of use of the invention are depicted in FIGS. 5through 7. In FIG. 5, the seal 1 is provided atop a door or window jamb20 between a brick veneer 11 and concrete block wall 10 in an invertedfashion as shown. In FIG. 6, the seal 1 is also inverted and arrangedbetween the exterior wall 11 comprised of brick that includes a weephole 22. Flashing 21 is arranged to run from the interior wall 10 to theweep hole 22 for draining condensation from between the walls 10, 11 ina known manner. In this instance, the flashing is disposed between anedge of the seal 1 and the weep hole 22, as shown. In FIG. 7, the seal 1is disposed between a plurality of bricks 25 that are arranged above thewindow or door jamb in a known manner.

It is to be understood that the invention is not limited to the exactconstruction illustrated and described above. Various changes andmodifications may be made without departing from the spirit and thescope of the invention as defined in the following claims.

1. A vapor barrier and cavity seal having a t-shape in profile andproviding a redundant seal in a cavity having a width and defined by aninterior and exterior wall of a building, said vapor barrier and cavityseal comprising: a head portion having a first width and bridging saidcavity; and, a body portion connected to said first portion and having asecond width that is less than the first width and being disposed withinsaid cavity.
 2. The vapor barrier and cavity seal of claim 1 furtherincluding an arcuate surface provided opposite the second portion. 3.The vapor barrier and cavity seal of claim 1 further including anextruded material of foam polyethylene.
 4. The vapor barrier and cavityseal of claim 1 comprising a closed cell, soft, flexible non-gassing rodof material.
 5. The vapor barrier and cavity seal of claim 1 whereinsaid cavity is formed between a brick veneer and framing.
 6. The vaporbarrier and cavity seal of claim 1 wherein said interior wall comprisesconcrete blocks.
 7. The vapor barrier and cavity seal of claim 1 whereinsaid exterior wall comprises brick.
 8. A vapor barrier and cavity sealthat seals a cavity defined by a distance between an interior andexterior wall of a building, said seal comprising: a rounded uppersurface having edges extended across the interior and exterior walls; alower portion attached to the rounded upper surface and having paralleledges and a bottom, said lower portion having a width that equals thedistance between the interior and exterior walls.
 9. The vapor barrierand cavity seal of claim 8 further including an extruded material offoam polyethylene.
 10. The vapor barrier and cavity seal of claim 8comprising a closed cell, soft, flexible non-gassing rod of material.11. The vapor barrier and cavity seal of claim 8 wherein said cavity isformed between a brick veneer and framing.
 12. A vapor barrier andcavity seal that seals a cavity having a width and being defined by twoparallel walls, said vapor barrier and cavity seal comprising: a headportion including an arcuate surface and spanning the entire widthacross the cavity; a body portion connected to said head portion andhaving a width that is substantially equal to the width of the cavity,said body portion being disposed between the parallel walls; and,wherein said vapor barrier comprises an extruded material.
 13. The vaporbarrier and cavity seal of claim 12 wherein a width of said head isgreater than the width of the body and cavity.
 14. The vapor barrier andcavity seal of claim 12 further including an extruded material of foampolyethylene.
 15. The vapor barrier and cavity seal of claim 12comprising a closed cell, soft, flexible non-gassing rod of material.16. The vapor barrier and cavity seal of claim 12 wherein said cavity isformed between a brick veneer and framing.
 17. The vapor barrier andcavity seal of claim 12 wherein said cavity is formed above a jamb andbetween a brick veneer and a concrete block.